5-Androsten-3beta-ol steroid intermediates and processes for their preparation

ABSTRACT

The present invention provides 5-androsten-3β-ol steroid intermediates and processes for their preparation.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of the following provisionalapplications: U.S. Ser. No. 60/403,990, filed Aug. 16, 2002, and U.S.Ser. No. 60/415,293, filed Oct. 1, 2002, under 35 USC 119(e)(i), each ofwhich is incorportated herein by reference in their entirety.

FIELD OF THE INVENTION

[0002] The present invention provides 5-androsten-3β-ol steroids andprocesses for their preparation.

BACKGROUND

[0003] Steroid intermediates are often useful in the production ofpharmaceutical agents. 5-androsten-3β,7β,11α-triol-17-one is a steroidintermediate useful for producing eplerenone.

SUMMARY OF INVENTION

[0004] In general, the present invention provides a practical fungalmethod for 7β- and 11α-hydroxylation of 5-androsten-3β-ol-17-one andother related analogues of the general formula (I) to yield5-androsten-3β,7β,11α-ol-triol-17-one and other related analogues of thegeneral formula (II and IV).

[0005] In one aspect, the invention features a 7β-hydroxy steroid of theformula (II)

[0006] where

[0007] R₃ is:

[0008] (1) —H;

[0009] (2) —CO—R₄

[0010] where R₄ is H or C₁-C₅ alkyl;

[0011] where R₁₇ and R₁₈ together form ═O or

[0012] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0013] where Z₁-Z₂ is either a single bond, or a double bond. Examplesof the 7β-hydroxy steroid (II) include, but are not limited to,5-androsten-3β,7β-diol-17-one and5,9(11)-androstadien-3β,7β-diol-17-one.

[0014] In another aspect, the invention features a 11α-hydroxy steroidof the formula

[0015] where

[0016] R₃ is:

[0017] (1) —H;

[0018] (2) —CO—R₄

[0019] where R₄ is H or C₁-C₅ alkyl;

[0020] where R₁₇ and R₁₈ together form ═O or

[0021] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0022] An example of the 11α-hydroxy steroid of formula (III) is5-androsten-3β,11α-diol-17-one.

[0023] In another aspect, the invention features a 7β,11α-dihydroxysteroid of the formula (IV)

[0024] where

[0025] R₃ is:

[0026] (1) —H;

[0027] (2) —CO—R₄

[0028] where R₄ is H or C₁-C₅ alkyl;

[0029] where R₁₇ and R₁₈ together form ═O or

[0030] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0031] An example of the 7β,11α-dihydroxy steroid of formula (IV) is5-androsten-3β,7β,11α-triol-17-one.

[0032] In still another aspect, the invention features a process for thepreparation of a 7β-hydroxy steroid of the formula (II)

[0033] where

[0034] R₃ is:

[0035] (1) —H;

[0036] (2) —CO—R₄

[0037] where R₄ is H or C₁-C₅ alkyl;

[0038] where R₁₇ and R₁₈ together form ═O or

[0039] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0040] where Z₁-Z₂ is either a single bond, or a double bond,

[0041] the process comprising

[0042] (1) contacting a Δ⁵-steroid of formula (I)

[0043] where R₃, R₁₇, R₁₈, and Z₁-Z₂ are as defined above, with7β-hydroxylase of Diplodia, e.g., Diplodia gossypina. Examples of the7β-hydroxy steroid (II) include, but are not limited to,5-androsten-3β,7β-diol-17-one and5,9(11)-androstadien-3β,7β-diol-17-one. The process of contacting may beby fermentation, cell concentrate, whole cells or cell-free reaction.

[0044] In another aspect, the invention features a process for thepreparation of an 11α-hydroxy steroid of the formula (III)

[0045] where

[0046] R₃ is:

[0047] (1) —H;

[0048] (2) —CO—R₄

[0049] where R₄ is H or C₁-C₅ alkyl;

[0050] where R₁₇ and R₁₈ together form ═O or

[0051] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0052] the process comprising:

[0053] (1) contacting a Δ⁵-steroid of formula (I)

[0054] where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is asingle bond with 11α-hydroxylase of Aspergillus, e.g., Aspergillusochraceus. An example of the 11α-hydroxy steroid is5-androsten-3β,11α-diol-17-one. The process of contacting may be byfermentation, cell concentrate, whole cells or cell-free reaction.

[0055] In yet another aspect, the invention features a process for thepreparation of a 7β,11α-dihydroxy steroid of the formula (IV)

[0056] where

[0057] R₃ is:

[0058] (1) —H;

[0059] (2) —CO—R₄

[0060] where R₄ is H or C₁-C₅ alkyl;

[0061] where R₁₇ and R₁₈ together form ═O or

[0062] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0063] the process comprising

[0064] (1) contacting a 7β-hydroxy steroid of formula (II)

[0065] where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is asingle bond with 11α-hydroxylase of Aspergillus, e.g., Aspergillusochraceus. An example of the 7β,11α-dihydroxy steroid (IV) is5-androsten-3β,7β,11α-triol-17-one. The process of contacting may be byfermentation, cell concentrate, whole cells or cell-free reaction.

[0066] In still a further aspect, the invention features a process forthe preparation of a 7β,11α-dihydroxy steroid of the formula (IV)

[0067] where

[0068] R₃ is:

[0069] (1) —H;

[0070] (2) —CO—R₄

[0071] where R₄ is H or C₁-C₅ alkyl;

[0072] where R₁₇ and R₁₈ together form ═O or

[0073] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0074] the process comprising

[0075] (1) contacting a Δ⁵-steroid of formula (I)

[0076] where R₃, R₁₈, and R₁₇ are as defined above and where Z₁-Z₂ is asingle bond between with 7β-hydroxylase of Diplodia, e.g., Diplodiagossypina, to produce a 7β-hydroxy steroid of formula (II)

[0077] where R₃, R₁₇, R₁₈, and Z₁-Z₂ are as defined above; and

[0078] (2) contacting the 7β-hydroxy steroid (II) of step (1) with11α-hydroxylase of Aspergillus, e.g., Aspergillus ochraceus. An exampleof the 7β,11α-dihydroxy steroid (IV) is5-androsten-3β,7β,11α-triol-17-one. The process for the preparation of a7β,11α-dihydroxy steroid (IV) where the 7β-hydroxy steroid (II) of step(1) may not be isolated prior to the contacting of step (2).

[0079] In another aspect, the invention features a process for thepreparation of a 7β,11α-dihydroxy steroid of the formula (IV)

[0080] where

[0081] R₃ is:

[0082] (1) —H;

[0083] (2) —CO—R₄

[0084] where R₄ is H or C₁-C₅ alkyl;

[0085] where R₁₇ and R₁₈ together form ═O or

[0086] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0087] the process comprising

[0088] (1) contacting a Δ⁵-steroid of formula ([)

[0089] where R₃, R₁₈, and R₁₇ are as defined above and where Z₁-Z₂ is asingle bond with the 7β,11α-hydroxylase(s) of Absidia, e.g., Absidiacoerulea. An example of the 7β,11α-dihydroxy steroid (IV) is5-androsten-3β,7β,11α-triol-17-one. The process of contacting may be byfermentation, cell concentrate, whole cells or cell-free reaction.

[0090] In yet another aspect, the invention features process for thepreparation of a 5,9(11)-androstadien of formula I

[0091] where

[0092] R₃ is:

[0093] (1) —H;

[0094] (2) —CO—R₄

[0095] where R₄ is H or C₁-C₅ alkyl;

[0096] where R₁₇ and R₁₈ together form ═O or

[0097] where R₁₇ and R₁₈ together with the C17 carbon atom of thesteroid backbone to which they are bound form a lactone ring of theformula

[0098] and where Z₁-Z₂ is a double bond, the process comprising: (1)providing a compound of the formula (III)

[0099] where R₃, R₁₇, and R₁₈ are as defined above; and (2) eliminatingthe 11αhydroxyl group to form the double bond between Z₁ and Z₂ (FormulaI). The step of providing the compound of formula III may includecontacting a Δ⁵-steroid of formula (I)

[0100] where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is asingle bond with 11α-hydroxylase of Aspergillus, e.g., Aspergillusochraceus.

[0101] Embodiments of each aspect of the invention may include one ormore of the following. R₃ is H. R₃ is —C(O)—CH₃. R₃ is —C(O)—H. R₁₇ andR₁₈ form ═O. R₁₇, R₁₈, and the C17 carbon atom of the steroid backboneform the lactone ring shown above. The lactone ring has the α and βstereochemistry shown in the formula

DEFINITIONS AND CONVENTIONS

[0102] The definitions and explanations below are for the terms as usedthroughout this entire document including both the specification and theclaims.

CONVENTIONS FOR FORMULAS AND DEFINITIONS OF VARIABLES

[0103] The chemical formulas representing various compounds or molecularfragments in the specification and claims may contain variablesubstituents in addition to expressly defined structural features. Thesevariable substituents are identified by a letter or a letter followed bya numerical subscript, for example, “Z_(i)” or “R_(i)” where “i” is aninteger.

DEFINITIONS

[0104] The definitions and explanations below are for the terms as usedthroughout this entire document including both the specification and theclaims.

[0105] All temperatures are in degrees Celsius.

[0106] r.p.m. refers to revolutions per minute.

[0107] TLC refers to thin-layer chromatography.

[0108] HPLC refers to high pressure liquid chromatography.

[0109] psig refers to pounds per square inch gage.

[0110] DO refers to dissolved oxygen.

[0111] RO refers to reverse osmosis.

[0112] SLM refers to standard liters per minute.

[0113] VVM refers to volume per minute.

[0114] OUR refers to oxygen uptake rate.

[0115] When solvent mixtures are used, the ratios of solvents used arevolume/volume (v/v).

DETAILED DESCRIPTION OF THE INVENTION

[0116] In general the invention relates to 7β,11α-dihydroxysteroids andprocesses for their preparation. Compounds of this invention may be usedin the production of Eplerenone. Scheme I illustrates one possiblemethod for using a 7β,11α-dihydroxysteroids to produce Eplerenone.

[0117] Referring to Scheme I, intermediate 2 may be produce by addinghexamethyldisilazane (HMDS) (100 ml) to a stirred slurry of 50.0 g Triol1 in 400 ml methylene chloride. Saccharin (0.57 g) is then added and themixture is heated under reflux for 3 hours during which time the slurrywill gradually dissolve to a clear, amber solution. Water (5 ml) isadded to quench any excess HMDS. After 5 minutes at reflux the mixtureis filtered through a CH₂Cl₂ wet layer of 32.6 g magnesol on a 350 mlcoarse frit filter funnel. The filtrate should be clear and almostcolorless. The filter cake is washed with 2×100 ml CH₂Cl₂. The combinedfiltrates are concentrated under reduced pressure and residual methylenechloride is removed by evaporation with 2×500 ml portions oftetrahydrofuran (THF), concentrating to dryness after each addition togive a white solid.

[0118] A suspension of potassium t-butoxide (42.0 g) in 500 ml THF iscooled to −9°±5° C. with an ice/methanol bath. Acetylene is bubbled intothe mixture just under the surface with moderate stirring at for atleast 1 hour. The silylated steroid intermediate from above in THF (400ml) is added over 30 min while maintaining a reaction temperature of0°±5° C. After the addition, the mixture is stirred for a further hourat 5°±5° C. Water (100 ml) is added slowly allowing the reaction mixtureto warm up to 15°±5° C. 125 ml of 10% HCl is slowly added to reduce thepH to 2.5 to 3. The mixture is stirred at pH 2.5 to 3, adding smallamounts of 5% HCl as needed to maintain a pH of 2.5 to 3, for 1 to 2hours at 20°±5° C. When the hydrolysis is complete, half saturatedNaHCO₃ solution is added to raise the pH to 5.5 to 6 . The mixture isdiluted with ethyl acetate (500 ml) and the phases separated. Theaqueous phase is extracted with ethyl acetate and the combined ethylacetate phases are washed with water, brine, dried over magnesiumsulfate and concentrated to give the addition product 2.

[0119] The intermediate 2 may be acylated by dissolving tetraol 2 (50.00g, 144 mmol) in pyridine (150 ml) and cooling the resulting mixture to<10° C. in an ice bath. Dimethylaminopyridine (DMAP) (1.7 g, 14 mmol) isadded followed by slow addition of acetic anhydride (41.4 ml, 439 mmol)at a rate to maintain the solution temperature below 10° C. Followingthe addition, the reaction mixture is warmed to room temperature. Themixture is diluted with ethyl acetate (75 ml) and water (50 ml), stirredfor 5 minutes and the layers separated. The organic layer is washed with10% HCl (4×25 ml) followed by H₂O (2×50 ml), dried over MgSO₄ andconcentrated. The product is recrystallized from toluene (100 ml).

[0120] Hydroformylation of the acylated intermediate 3 may be producedby heating compound 3 (25.4 g, 54 mmol) with PPh₃ (2.13 g, 8.1 mmol) andRh₂(OAc)₄ (716 mg, 1.62 mmol) in ethyl acetate (200 ml) to about 80° C.under a 1/1 mixture of hydrogen/carbon monoxide at a pressure of 170 psifor 12 hours. The mixture is concentrated under reduced pressure and theproduct 4 purified by column chromatography (70/30 EtOAc/Hex and 500 gsilica).

[0121] Oxidation of the lactol compound 4 may be accomplished by mixingthe lactol 4 (25 g, 50 mmol), methylene chloride(250 ml), water (38 ml),2,2,6,6-tetramethylpiperidin-1-oxyl (TEMPO) (156 mg, 1 mmol), KBr (595mg, 5 mmol), and NaHCO₃ (5.5 g, 65 mmol) and cooling the mixture to ≦10°C. in an ice bath. A solution of 1.1 M sodium hypochlorite (NaOCl) (50ml, 55 mmol) is slowly added. The mixture is allowed to warm to roomtemperature and diluted with water (50 ml). The layers are separated andthe organic layer washed with brine (2×50 ml). The organic layer isdried with MgSO₄, filtered and concentrated to afford 5 as an off whitefoam.

[0122] Heating a mixture of the triacetate 5 (2.0 g), Pd(dppp)Br₂ (126mg), diisopropyl amine (0.78 mL), Et₄NBr(260 mg), NaBr (1.09 g) in 20 mlof methanol under 1200 psi of CO at 65° C. for twelve hours, followed bycooling, concentrating, and chromatographing the residue on silica gelwith 40-75% ethyl acetate/hexane gives the methyl ester 6.

[0123] A solution of the diacetylester 6 (5.01 g) in 0.15N potassiumcarbonate in methanol (50 ml) is stirred at room temperature and thereaction monitored by TLC. When the starting material 6 is no longerdetected the mixture is diluted with water (200 ml) and extracted withethyl acetate (3×200 ml). The combined extracts are washed with water(100 ml), brine (100 ml), dried over magnesium sulfate and concentratedat reduced pressure to dryness. The residue is chromatographed oversilica gel with ethyl acetate/hexane gives the 3-hydroxy compound 7.

[0124] A mixture of alcohol 7 (6.0 g), CH₂Cl₂ (40 mL), water (9.0 mL),2,2,6,6-tetramethylpiperidine-1-oxyl (TEMPO) (38 mg), KBr (142 mg) andsodium bicarbonate (4.0 g) is cooled to 5° C. To this mixture is slowlyadded 14.1 ml of 1.1 M NaOCl. After the addition the mixture is allowedto stir for an additional 1 h and acidified with dilute HCl. The product8 is isolated with CH₂Cl₂.

[0125] A solution of the compound 8 (5.01 g) in 0.15N potassiumcarbonate in methanol (50 ml) is stirred at room temperature and thereaction monitored by TLC. When the starting material 8 is no longerdetected the mixture is diluted with water (200 ml) and extracted withethyl acetate (3×200 ml). The combined extracts are washed with water(100 ml), brine (100 ml), dried over magnesium sulfate and concentratedat reduced pressure to dryness. The residue is chromatographed oversilica gel with ethyl acetate/hexane to give compound 9.

[0126] PCl₅ (1.08 g) is added to a solution of compound 9 in THF at −51°C. which results in a temperature rise to −48° C. After 2 hrs themixture is poured into aqueous NaHCO₃ and extracted with EtOAc andconcentrated. The material was chromatographed on silica gel withEtOAc/hexane to afford the diene compound 10.

[0127] Eperlernone is produced by epoxidation of compound 10 by knownmethods described, for example, in U.S. Pat. Nos. 4,559,332, and5,981,744, the contents of which are incorporated in their entirety byreference.

[0128] Referring to Chart A, androst-5-en-17-one compounds of formula(I) may be converted to different steroid intermediates via fungalreactions. For instance, contacting androst-5-en-7-one compounds offormula (I), where Z₁-Z₂ is either a single bond or a double bond, withDiplodia gossypina produces 7β-hydroxy androst-5-en-17-one compounds offormula (II). 11α-hydroxyandrost-5-en-17-one compounds of formula (III)are produced by contacting androst-5-en-17-one compounds of formula (I),where Z₁-Z₂ is a single bond, with Aspergillus ochraceus. Surprisingly,contacting 11α-hydroxyandrost-5-en-17-one compounds of formula (III)with Diplodia gossypina fails to produce the7β,11α-dihydroxyandrost-5-en-17-one compounds of formula (IV), whereascontacting 7β-hydroxyandrost-5-en-17-one compounds of formula (II),where Z₁-Z₂ is a single bond, with Aspergillus ochraceus produces7β,11α-dihydroxyandrost-5-en-17-one compounds of formula (IV).Unexpectedly, contacting androst-5-en-17-one compounds of formula (1),where Z₁-Z₂ is a single bond with Absidia coerulea directly produces7β,11α-dihydroxyandrost-5-en-17-one compounds of formula (IV).

[0129] The filamentous fungi reactants belong to the genera Dipodia(synonyms Botryodiplodia, Lasiodiplodia), Aspergillus, and Absidiacoerulea, and are generally prepared by a primary and a secondaryvegetative seed stage. The secondary seed is utilized to inoculate thesteroid bioconversion stage.

[0130] The processes disclosed herein may be used to produce steroidcompounds of formula (I), (II), (III), and (IV), that are usefulintermediates for the manufacture of pharmaceutically active steroidssuch as aldosterone receptor antagonists. In addition,5-androsten-3β,7β-diol-17-one (formula II wherein R₃ is a hydrogen andR₁₇ and R₁₈ together are a ketone, and Z₁-Z₂ is a single bond) is anattractive intermediate for the synthesis of5-androsten-3β-ol-7,17-dione, a commercially available steroidsupplement that has been postulated to have beneficial effects on heartdisease, immune function, aging, and general well-being.

[0131] Detailed Description of the 7β-Hydroxylation Step

[0132] Steroid compounds of formula (I), where Z₁-Z₂ is a single bond ora double bond, are microbiologically hydroxylated at the 7-position toproduce steroid compounds of formula (II), where Z₁-Z₂ is a single bondor a double bond.

[0133] Any filamentous fungus of the genus Diplodia, Botryodiplodia, orLasiodiplodia capable of 7β-hydroxylating steroids of formula (I) can beused in the invention process. Preferably, Diplodia gossypina ATCC 20571(synonym Botryodiplodia theobromae IFO 6469) or Botryodiplodia malorumATCC 24444 (synonym CBS 134.50) are used. More preferably, Diplodiagossypina ATCC 20571 (synonym Botryodiplodia theobromae IFO 6469) isused.

[0134] The fungal hydroxylase may be utilized in the form of an activelygrowing culture, a whole-cell concentrate, or a cell-free extract.Preferably the fungus is grown in submerged culture under aerobicconditions, using any art-recognized procedure, and the 7β-hydroxylationreaction performed in situ.

[0135] The desired fungus may be cultured under conditions set forth inEXAMPLEs 1 and 2 using the ingredients specified, or other suitablecarbon and nitrogen sources as are known to those skilled in the art.Generally a primary and secondary vegetative seed procedure is used inpreparation for the fungal 7β-hydroxylation. Alternatively, a primaryvegetative seed can be used directly to inoculate bioconversion media.

[0136] Primary vegetative seed cultures may be incubated for a period ofabout 24 to about 96 hours (preferably about 48-72 hours) at atemperature between about 20° and about 37° (preferably about 28°), anda pH between about 3.0 and about 7.5. Secondary vegetative seed mediumis inoculated with about 0.006% to about 0.1% (v/v) primary vegetativeseed culture, but typically about 0.012% (v/v), and incubated for aperiod of about 36 to about 72 hours (preferably about 60 hours) at atemperature between about 20° and about 37° (preferably about 28°). ThepH of the secondary seed medium can be between about 2.5 and about 7.0,but preferably between about 3.0 and about 5.0. The bioconversionmedium, which can be the same or similar to the secondary vegetativeseed medium, is inoculated with about 1% to about 10% (v/v) secondaryvegetative seed culture (preferably about 3% to about 5%). After aninitial incubation period of about 12 to about 72 hours (preferablyabout 16 to about 24 hours), steroid substrates of formula (I),preferably micronized, are added to the bioconversion culture.Micronized steroid substrates of formula (I) can be added as a drypowder or an aqueous slurry, either as a single addition, a series ofadditions, or a continual feed. It is preferred to use the micronizedsteroid substrates of formula (I) at a concentration greater than 1 g/L,more preferably greater than 2.5 g/L, even more preferably greater than5 g/L. Bioconversion of steroid substrates of formula (I) to form7β-hydroxylated products of formula (II), respectively, is allowed toproceed for between about 2 and about 6 days, but typically about 3 toabout 4 days.

[0137] The rate and extent of 7β-hydroxylation can be greatly improvedby: (i) culturing the selected fungus, and performing the bioconversion,in the presence of a detergent. The detergent may be selected from thegroup consisting of non-ionic detergents, but preferably the sub-groupsconsisting of ethoxylated alkylphenols and polyoxyethylenesorbitanesters. More preferably, polyoxyethylenesorbitan monooleate is used;(ii) culturing the selected fungus, and performing the bioconversion, inthe presence of a natural oil. The natural oil may be selected from, butnot restricted to, the group consisting of caster oil, corn oil,cottonseed oil, lard oil, linseed oil, olive oil, peanut oil, rapeseedoil, safflower seed oil, soybean oil, sunflower seed oil, and wheat germoil. Preferably, soybean oil is used; (iii) using a combination of themethodologies identified in (i) and (ii).

[0138] Once the bioconversion of steroid substrates of formula (I) to7β-hydroxylated products of formula (II) is complete, compounds offormula (II) can be isolated using any one of a number of art-recognizedprocedures. Preferably, filtered or centrifuged beer solids areextracted using an organic solvent, such as methanol, acetone, butylacetate, or methylene chloride and the 7β-hydroxylated product offormula (II) is isolated by crystallization. The crystallizationsolvents include a solvent selected from, but not restricted to, thegroup consisting of water, methanol, acetone, butyl acetate, methylenechloride, or combinations thereof. The preferred extraction andcrystallization solvent for the 7β-hydroxylated product of formula (II)is methylene chloride.

[0139] Detailed Description of the 11α-Hydroxylation Step

[0140] Steroid compounds of formula (I) or (II), where Z₁-Z₂ is a singlebond are microbiologically hydroxylated at the 11-position to producesteroid compounds of formula (III) or (IV), respectively.

[0141] Any filamentous fungus of the genus Aspergillus capable of11α-hydroxylating steroids of formula (I) or (II), where Z₁-Z₂ is asingle bond can be used in the invention process. Preferably,Aspergillus ochraceus ATCC 18500 (synonym NRRL 405) is used.

[0142] The fungal hydroxylase may be utilized in the form of an activelygrowing culture, a whole-cell concentrate, or a cell-free extract.Preferably the fungus is grown in submerged culture under aerobicconditions, using any art-recognized procedure, and the11α-hydroxylation reaction performed in situ.

[0143] The desired fungus may be cultured under conditions set forth inEXAMPLEs 3 and 4 using the ingredients specified, or other suitablecarbon and nitrogen sources as are known to those skilled in the art.Generally a primary and secondary vegetative seed procedure is used inpreparation for the fungal 11α-hydroxylation. Alternatively, a primaryvegetative seed can be used directly to inoculate bioconversion media.

[0144] Primary vegetative seed cultures may be incubated for a period ofabout 24 to about 96 hours (preferably about 48-72 hours) at atemperature between about 20° and about 37° (preferably about 28°), anda pH between about 3.0 and about 7.5. Secondary vegetative seed mediumis inoculated with about 0.006% to about 0.1% (v/v) primary vegetativeseed culture, but typically about 0.012% (v/v), and incubated for aperiod of about 36 to about 72 hours (preferably about 60 hours) at atemperature between about 20° and about 37° (preferably about 28°). ThepH of the secondary seed medium can be between about 2.5 and about 7.0,but preferably between about 3.0 and about 5.0. The bioconversionmedium, which can be the same or similar to the secondary vegetativeseed medium, is inoculated with about 1% to about 10% (v/v) secondaryvegetative seed culture (preferably about 3% to about 5%). After aninitial incubation period of about 12 to about 72 hours (preferablyabout 16 to about 24 hours), steroid substrates of formula (I) or (II),where Z₁-Z₂ is a single bond, are added to the bioconversion culture.Preferably the substrates are micronized.

[0145] Micronized steroid substrates of formula (I) or (II), where Z₁-Z₂is a single bond, can be added as a dry powder or an aqueous slurry,either as a single addition, a series of additions, or a continual feed.It is preferred to use the micronized steroid substrates of formula (I)or (II), where Z₁-Z₂ is a single bond, at a concentration greater than 1g/L, more preferably greater than 2.5 g/L, even more preferably greaterthan 5 g/L. Bioconversion of steroid substrates of formula (I) or (II),where Z₁-Z₂ is a single bond, to form 11α-hydroxylated products offormula (III) or (IV), respectively, is allowed to proceed for betweenabout 1 and about 6 days, but typically about 2 to about 3 days.

[0146] The rate and extent of 11α-hydroxylation can be greatly improvedby: (i) culturing the selected fungus, and performing the bioconversion,in the presence of a detergent. The detergent may be selected from thegroup consisting of non-ionic detergents, but preferably the sub-groupsconsisting of ethoxylated alkylphenols and polyoxyethylenesorbitanesters. More preferably, octylphenoxypolyethoxyethanol ornonylphenoxypolyethoxyethanol is used; (ii) culturing the selectedfungus, and performing the bioconversion, in the presence of naturaloil. The natural oil may be selected from, but not restricted to, thegroup consisting of caster oil, corn oil, cottonseed oil, lard oil,linseed oil, olive oil, peanut oil, rapeseed oil, safflower seed oil,soybean oil, sunflower seed oil, and wheat germ oil. Preferably, soybeanoil is used; (iii) using a combination of the methodologies identifiedin (i) and (ii).

[0147] Once the bioconversion of steroid substrates of formula (I) or(II), where Z₁-Z₂ is a single bond to 11α-hydroxylated products offormula (III) or (IV) is complete, compounds of formula (III) or (IV)can be isolated using any one of a number of art-recognized procedures.Preferably, filtered or centrifuged beer solids, or whole beers, areextracted using a water-miscible organic solvent, such as methanol oracetone at temperatures as low as about 15° C. or as high as about 55°C. The preferred extraction temperature is about 45-50° C. The crude11α-hydroxylated product of formula (III) or (IV) is generated byevaporative crystallization, to remove the organic solvent, and cooling.The preferred extraction solvent mixture is 80-85% acetone/15-20% water.The spent aqueous liquor is discarded.

[0148] Crude crystalline 11α-hydroxylated product of formula (III) or(IV), is purified by carbon treatment and crystallization. It ispreferred that the carbon treatment and subsequent crystallization bedone using a water-miscible solvent selected from, but not restrictedto, the group consisting of methanol or acetone. The preferredcarbon-treatment/crystallization solvent is methanol. After removal ofcarbon by filtration, the crystallization is performed by evaporation ofsolvent and cooling.

[0149] Compounds of formula (I) where Z₁-Z₂ is a double bond may beproduced by eliminating the 11α-hydroxyl from the product of formula(III) using known chemical methods.

[0150] Detailed Description of the 7β,11α-Dihydroxylation Step

[0151] Steroid compounds of formula (I), where Z₁-Z₂ is a single bondare microbiologically hydroxylated at the 7- and 11-position, in asingle step, to produce steroid compounds of formula (IV).

[0152] Any filamentous fungus of the genus Absidia capable of7β,11α-dihydroxylating steroids of formula (I), where Z₁-Z₂ is a singlebond can be used in the invention process. Preferably, Absidia coeruleaATCC 6647 (synonym Absidia orchidis) is used.

[0153] The fungal hydroxylase(s) may be utilized in the form of anactively growing culture, a whole-cell concentrate, or a cell-freeextract. Preferably the fungus is grown in submerged culture underaerobic conditions, using any art-recognized procedure, and the 7β- and11α-hydroxylation reactions performed in situ.

[0154] The desired fungus may be cultured under conditions set forth inEXAMPLE 5 using the ingredients specified, or other suitable carbon andnitrogen sources as are known to those skilled in the art. Generally aprimary and secondary vegetative seed procedure is used in preparationfor the fungal 7β,11α-dihydroxylation. Alternatively, a primaryvegetative seed can be used directly to inoculate bioconversion media.

[0155] Primary vegetative seed cultures may be incubated for a period ofabout 24 to about 96 hours (preferably about 48-72 hours) at atemperature between about 20° and about 37° (preferably about 28°), anda pH between about 3.0 and about 7.5. Secondary vegetative seed medium,which can be the same or similar to the primary vegetative seed medium,is inoculated with about 0.006% to about 0.1% (v/v) primary vegetativeseed culture, but typically about 0.012% (v/v), and incubated for aperiod of about 36 to about 96 hours (preferably about 70 to 80 hours)at a temperature between about 20° and about 37° (preferably about 28°).The pH of the secondary seed medium can be between about 2.5 and about7.5, but preferably between about 3.0 and about 7.0. The bioconversionmedium, which can be the same or similar to the secondary vegetativeseed medium, is inoculated with about 1% to about 10% (v/v) secondaryvegetative seed culture (preferably about 3% to about 5%). After aninitial incubation period of about 12 to about 72 hours (preferablyabout 15 to about 24 hours), steroid substrates of formula (I), whereZ₁-Z₂ is a single bond, are added to the bioconversion culture.Preferably the substrates are micronized. Micronized steroid substratesof formula (I), where Z₁-Z₂ is a single bond, can be added as a drypowder or an aqueous slurry, either as a single addition, a series ofadditions, or a continual feed. It is preferred to use the micronizedsteroid substrates of formula (I), where Z₁-Z₂ is a single bond, at aconcentration greater than 1 g/L, more preferably greater than 2.5 g/L,even more preferably greater than 5 g/L. Bioconversion of steroidsubstrates of formula (I), where Z₁-Z₂ is a single bond, to form11α-hydroxylated products of formula (IV), is allowed to proceed forbetween about 2 and about 9 days, but typically about 5 to about 7 days.Once the bioconversion of steroid substrates of formula (I), where Z₁-Z₂is a single bond, to 7β,11α-dihydroxylated products of formula (IV) iscomplete, compounds of formula (IV) can be isolated using any one of anumber of art-recognized procedures. Preferably, filtered or centrifugedbeer solids, or whole beers, are extracted using a water-miscibleorganic solvent, such as methanol or acetone at temperatures as low asabout 15° C. or as high as about 55° C. The preferred extractiontemperature is about 45-50° C. The crude 7β,11α-dihydroxylated productof formula IV is generated by evaporative crystallization, to remove theorganic solvent, and cooling. The preferred extraction solvent mixtureis 80% acetone/20% water. The spent aqueous liquor is discarded.

[0156] Crude crystalline 7β,11α-dihydroxylated product of formula (IV)is purified by a methylene chloride trituration to remove unwantedimpurities, followed by carbon treatment and crystallization. It ispreferred that the carbon treatment and subsequent crystallization bedone using a water-miscible solvent selected from, but not restrictedto, the group consisting of methanol or acetone or mixtures. Thepreferred carbon-treatment/crystallization solvent is methanol. Afterremoval of carbon by filtration, product crystallization is achieved byevaporation of the solvent and cooling.

EXAMPLES

[0157] Without further elaboration, it is believed that one skilled inthe art can, using the preceding descriptions, practice the presentinvention to its fullest extent. The following detailed examplesdescribe how to prepare the various compounds and/or perform the variousprocesses of the invention and are to be construed as merelyillustrative, and not limitations of the preceding disclosure in any waywhatsoever. Those skilled in the art will promptly recognize appropriatevariations from the procedures both as to reactants and as to reactionconditions and techniques.

[0158] 3β-hydroxyandrost-5-en-17-one, also referred to as5-androsten-3β-ol-17-one, is available from Jiangsu WujinPharmaceuticals located in China.

Example 1

[0159] Bioconversion of 5-androsten-3β-ol-17-one (I, where R₃=hydrogen,R_(17,18)=ketone, and Z₁-Z₂ is a single bond to5-androsten-3β,7β-diol-17-one (II, where R₃=hydrogen, R_(17,18)=ketone,and Z₁-Z₂ is a single bond)

[0160] The bioconversion of 5-androsten-3β-ol-17-one to5-androsten-3β,7β-diol-17-one is performed using a submerged culture ofDiplodia gossypina ATCC 20571 (synonym Botryodiplodia theobromae IFO6469) at a 10-L fermentation scale.

[0161] (A) Primary-Seed Stage

[0162] Frozen vegetative cells of Diplodia gossypina ATCC 20571 arethawed, transferred to potato-dextrose-agar plates (PDA), and incubatedat 28° for 72 hours. Single mycelial-plugs (6-7 mm diam.) are used toinoculate siliconized 500-mL stippled shakeflasks containing 100 mLprimary-seed medium. Primary-seed medium consists of (per liter of ROwater): dextrin, 50 g; soyflour, 35 g; cerelose, 5 g; cobalt chloridehexahydrate, 2 mg; silicone defoamer (SAG 471), 0.5 mL;pre-sterilization pH 7.0-7.2, adjusted with sodium hydroxide (2N).Diplodia gossypina ATCC 20571 is incubated for 48 hours at 28°, using acontrolled-environment incubator-shaker set at 280 r.p.m. (1″ orbitalstroke).

[0163] (B) Secondary-Seed Stage

[0164] Ten-liter secondary-seed fermentations are inoculated using 1.2mL vegetative primary-seed culture (0.012% [v/v] inoculation rate).Secondary-seed medium contains (per liter of RO water): cerelose, 60 g;soyflour, 25 g; soybean oil, 30 mL; magnesium sulfate heptahydrate, 1 g;potassium dihydrogen phosphate, 0.74 g; polyoxyethylenesorbitanmonooleate, 2 mL; silicone defoamer (SAG 471), 0.5 mL; pre-sterilizationpH 3.95-4.00, adjusted with concentrated sulfuric acid. The fermentors,containing secondary-seed medium, are sterilized for 20 minutes at 121°using both jacket and injection steam. The agitation rate duringsterilization is 200 r.p.m. Post-sterilization, the medium pH isadjusted to 4.0 using sterile sulfuric acid (5%). Diplodia gossypinaATCC 20571 is incubated at 28° using the following initial parameters:agitation, 100 r.p.m.; back pressure=5 psig; airflow=2.5 SLM (0.25 VVM);low DO set-point, 30%; pH control, none. When the DO first drops to 30%,the airflow is increased to 5 SLM (0.5 VVM). When the culture reacheslow DO again, 30% DO is maintained using agitation control.Secondary-seed cultures are harvested at approximately 60 hourspost-inoculation, when the OUR is between about 10 and about 15 mM/L/h.

[0165] (C) Steroid Bioconversion

[0166] Ten-liter steroid-bioconversion fermentations are inoculatedusing 500 mL vegetative secondary-seed culture (5% [v/v] inoculationrate). Steroid-bioconversion medium is the same as secondary-seedmedium. Sterilization conditions and pH adjustment are as described forsecondary-seed medium. Diplodia gossypina ATCC 20571 is incubated at 28°using essentially the same initial parameters as those used forsecondary-seed cultivation, with the exception that the low DO set-pointis increased from 30% to 50%. When the DO first drops to 50%, the airflow is increased from 2.5 SLM (0.25 VVM) to 5 SLM (0.5 VVM). When theculture reaches low DO again, 50% DO is maintained using agitationcontrol. Starting at 24 hours post-inoculation, micronized5-androsten-3β-ol-17-one, slurried in a minimal volume of 0.2%polyoxyetbylenesorbitan monooleate, is added to the fermentation inone-hour intervals until 400 g total is added. At about 3 dayspost-inoculation, an additional 100 g cerelose is added to the 10-Lfermentation.

[0167] Bioconversion cultures are assayed on a daily basis for5-androsten-3β,7β-doil-17-one using TLC. One milliliter of whole beer isextracted with 10 mL methanol. Cells are separated from theaqueous-methanol mixture by centrifugation (3,000×g for 10 minutes), andseveral microliters applied to a TLC plate. The TLC plate is developedin cyclohexane:ethyl acetate:methanol (90:60:15) and the productvisualized by spraying the TLC with 50% sulfuric acid, followed bycharring in an oven. Product is compared with authentic standard, whichturns blue on spraying with 50% sulfuric acid. Bioconversion of5-androsten-3β-ol-17-one to 5-androsten-3β,7β-diol-17-one is completeapproximately 4 days post-inoculation.

[0168] (D) Isolation Procedure

[0169] The whole beer at harvest is centrifuged and the rich solids arerecovered by centrifugation. The rich solids are extracted with 10liters of methylene chloride and the rich extract is recovered bycentrifugation. The extract is polished and concentrated to about1-liter by distillation and the crystal slurry is cooled to −10° C. Thecrystals are recovered by filtration, washed with cold methylenechloride to remove color, and dried to give 227 grams of purifiedcrystalline 5-androsten-3β,7β-diol-17-one.

Example 2

[0170] Bioconversion of 5,9(11)-androstadien-3β-ol-17-one (I, whereR₃=hydrogen, R_(17,18)=ketone, and Z₁-Z₂ is a double bond to5,9(11)-androstadien-3β,7β-diol-17-one (II, where R₃=hydrogen,R_(17,18)=ketone, and Z₁-Z₂ is a double bond

[0171] The bioconversion of 5,9(11)-androstadien-3β-ol-17-one to5,9(11)-androstadien-3β,7β-diol-17-one is performed using a submergedculture of Diplodia gossypina ATCC 20571 (synonym Botryodiplodiatheobromae IFO 6469) at a 10-L fermentation scale.

[0172] (A) Primary-Seed Stage

[0173] Primary-seed cultures are prepared as described in EXAMPLE 1.

[0174] (B) Secondary-Seed Stage

[0175] Ten-liter secondary-seed cultures are prepared as described inEXAMPLE 1.

[0176] (C) Steroid Bioconversion

[0177] Ten-liter steroid-bioconversion cultures are prepared asdescribed in EXAMPLE 1. At about 24 hours post-inoculation, 120 gmicronized 5,9(11)-androstadien-3β-ol-17-one, slurried in a minimalvolume of 0.2% polyoxyethylenesorbitan monooleate, is added to the 10-Lfermentation.

[0178] Bioconversion cultures are assayed on a daily basis for5,9(11)-androstadien-3β,7β-diol-17-one using the procedure described inEXAMPLE 1. Bioconversion of 5,9(11)-androstadien-3β-ol-17-one to5,9(11)-androstadien-3β,7β-diol-17-one is complete approximately 3 dayspost-inoculation.

[0179] (D) Isolation Procedure

[0180] The rich solids from the whole beer are recovered bycentrifugation. The liquid beer phase is extracted using 15 liters ofmethylene chloride. After settling, the upper spent beer layer isdecanted and discarded. The remaining rich methylene chloride is thenused to extract the rich solids. The resulting rich methylene chlorideextract is drained from the spent solids, polished, concentrated bydistillation to about 0.5 liters, and cooled to −10° C. The crystalsobtained are recovered by filtration, washed with n-butyl acetate toremove color, and dried to give 52.2 grams of purified crystalline5,9(11 )-androstadien-3β,7β-diol-17-one.

EXAMPLE 3

[0181] Bioconversion of 5-androsten-3β-ol-17-one (I, where R₃=hydrogen,R_(17,18)=ketone, and Z₁-Z₂ is a single bond to5-androsten-3β,11α-diol-17-one (II, where R₃=hydrogen, R_(17,18)=ketone,and Z₁-Z₂ is a single bond)

[0182] The bioconversion of 5-androsten-3β-17-one to5-androsten-3β,11α-diol-17-one is performed using a submerged culture ofAspergillus ochraceus ATCC 18500 (synonym NRRL 405) at a 10-Lfermentation scale.

[0183] (A) Primary-Seed Stage

[0184] Primary-seed cultures of Aspergillus ochraceus ATCC 18500 areprepared as described for Diplodia gossypina ATCC 20571 in EXAMPLE 1.

[0185] (B) Secondary-Seed Stage

[0186] Ten-liter secondary-seed fermentations are inoculated using 1.2mL vegetative primary-seed culture (0.012% [v/v] inoculation rate).Secondary-seed medium contains (per liter of RO water): cerelose, 40 g;soyflour, 25 g; soybean oil, 30 mL; magnesium sulfate heptahydrate, 1 g;potassium dihydrogen phosphate, 0.74 g; nonylphenoxypolyethoxyethanol,0.25 mL; silicone defoamer (SAG 471), 0.5 mL; pre-sterilization pH3.95-4.00, adjusted with concentrated sulfuric acid. The fermentors,containing secondary-seed medium, are sterilized for 20 minutes at 121°using both jacket and injection steam. The agitation rate duringsterilization is 200 r.p.m. Post-sterilization, the medium pH isadjusted to 4.0 using sterile sulfuric acid (5%). Aspergillus ochraceusATCC 18500 is incubated at 28° using the following initial parameters:agitation, 100 r.p.m.; back pressure=5 psig; airflow=2.5 SLM (0.25 VVM);low DO set-point, 50%; pH control, none. When the DO first drops to 50%,the airflow is increased to 5 SLM (0.5 VVM). When the culture reacheslow DO again, 50% DO is maintained using agitation control.Secondary-seed cultures are harvested between 50 to 54 hourspost-inoculation, when the OUR is between about 20 and about 26 mM/L/h.

[0187] (C) Steroid Bioconversion

[0188] Ten-liter steroid-bioconversion fermentations are inoculatedusing 500 mL vegetative secondary-seed culture (5% [v/v] inoculationrate). Steroid-bioconversion medium is essentially the same assecondary-seed medium, with the exception that thenonylphenoxypolyethoxyethanol is increased from 0.25 mL/L to 2 mL/L, andpre-sterilization pH is adjusted to 2.95-3.00 with concentrated sulfuricacid. Sterilization conditions are as described for secondary-seedmedium. Post-sterilization, the medium pH is adjusted to 3.0 usingsterile sulfuric acid (5%). Aspergillus ochraceus ATCC 18500 isincubated at 28° using essentially the same initial parameters as thoseused for secondary-seed cultivation, with the exception that agitationis initially set at 200 r.p.m. At about 18 hours post-inoculation, 200 gmicronized 5-androsten-3β-ol-17-one, slurried in a minimal volume of0.2% nonylphenoxypolyethoxyethanol, is added to the 10-L fermentation.

[0189] Bioconversion cultures are assayed on a daily basis for5-androsten-3β,11α-diol-17-one using TLC. One milliliter of whole beeris extracted with 19 mL methanol. Cells are separated from theaqueous-methanol mixture by centrifugation (3,000×g for 10 minutes), andseveral microliters applied to a TLC plate. The TLC plate is developedin cyclohexane:ethyl acetate:methanol (90:60:15) and the productvisualized by spraying the TLC with 50% sulfuric acid, followed bychafring in an oven. Bioconversion of 5-androsten-3β-ol-17-one to5-androsten-3β,11α-diol-17-one is complete approximately 3 dayspost-inoculation.

[0190] (D) Isolation Procedure

[0191] The whole beer solids are recovered by centrifugation. The liquidis discarded. The rich solids are extracted with 10 liters of 85%acetone 15% water at 45° C. to 50° C. and the rich extract is recoveredby centrifugation. The extract is concentrated by distillation to removeacetone to generate an aqueous slurry of crude crystals. The crudecrystals are recovered by filtration and the mother liquor is discarded.The water-wet crude crystals are dissolved in 700 milliliters ofmethanol by heating to 55° C. and then decolonized with 5 grams of DarcoG-60 carbon. After filtration to remove carbon, the filtrate isconcentrated to crystallize the product. The methanol is removed furtherby adding 300 mL of n-butyl acetate and concentrating to a thick crystalslurry. The crystals are filtered, washed with n-butyl acetate, anddried to give 174 grams of purified crystalline5-androsten-3β,11α-diol-17-one.

Example 4

[0192] Bioconversion of 5-androsten-3β,7β-diol-17-one (II, whereR₃=hydrogen, R_(17,18)=ketone, and Z₁-Z₂ is a single bond to5-androsten-3β,7β,11α-triol-17-one (IV, where R₃=hydrogen,R_(17,18)=ketone)

[0193] The bioconversion of 5-androsten-3β,7β-diol-17-one to5-androsten-3β,7β,11α-triol-17-one is performed using a submergedculture of Aspergillus ochraceus ATCC 18500 (synonym NRRL 405) at a 10-Lfermentation scale.

[0194] (A) Primary-Seed Stage

[0195] Primary-seed cultures of Aspergillus ochraceus ATCC 18500 areprepared as described in EXAMPLE 3.

[0196] (B) Secondary-Seed Stage

[0197] Ten-liter secondary-seed cultures of Aspergillus ochraceus ATCC18500 are prepared as described in EXAMPLE 3.

[0198] (C) Steroid Bioconversion

[0199] Ten-liter steroid-bioconversion cultures of Aspergillus ochraceusATCC 18500 are prepared as described in EXAMPLE 3.

[0200] At about 18 hours post-inoculation, 200 g micronized5-androsten-3β,7β-diol-17-one, slurried in a minimal volume of 0.2%nonylphenoxypolyethoxyethanol, is added to the 10-L fermentation.

[0201] Bioconversion cultures are assayed on a daily basis for5-androsten-3β,7β,11α-triol-17-one using TLC, as described in EXAMPLE 1.Bioconversion of 5-androsten-3β,7β-diol-17-one to5-androsten-3β,7β,11α-triol-17-one is complete approximately 4 dayspost-inoculation.

[0202] (D) Isolation Procedure

[0203] The whole beer solids are recovered by centrifugation. The liquidis discarded. The rich solids are extracted with 10 liters of 80%acetone 20% water at 45° C. to 50° C. and the warm extract is clarifiedby filtration. The rich filtrate is concentrated by distillation toremove acetone generating an aqueous slurry of crude crystals. The crudecrystals are recovered by filtration and the mother liquor is discarded.The water-wet crystals are triturated in 600 milliliters of methylenechloride to remove impurities, dissolved in 700 milliliters of methanol(by heating to 55° C.), and then decolorized with 5 grams of Darco G-60carbon. After filtration to remove carbon, the filtrate is concentratedto crystallize the product. The methanol is removed further by adding300 mL of n-butyl acetate and concentrating to a thick crystal slurry.The crystals are filtered, washed with n-butyl acetate, and dried togive 158 grams of purified crystalline5-androsten-3β,7β,11α-triol-17-one.

Example 5

[0204] Bioconversion of 5-androsten-3β-ol-17-one (I, where R₃=hydrogen,R_(17,18)=ketone, and Z₁-Z₂ is a single bond to5-androsten-3β,7β,11α-triol-17-one (IV, where R₃=hydrogen,R_(17,18)=ketone)

[0205] The bioconversion of 5-androsten-3β-ol-17-one to5-androsten-3β,7β,11α-triol-17-one is performed using a submergedculture of Absidia coerulea ATCC 6647 (synonym Absidia orchidis) at a10-L fermentation scale.

[0206] (A) Primary-Seed Stage

[0207] Primary-seed cultures of Absidia coerulea ATCC 6647 are preparedas described for Diplodia gossypina ATCC 20571 in EXAMPLE 1.

[0208] (B) Secondary-Seed Stage

[0209] Ten-liter secondary-seed fermentations are inoculated using 1.2mL vegetative primary-seed culture (0.012% [v/v] inoculation rate).Secondary-seed medium contains (per liter of RO water): dextrin, 50 g;soyflour, 35 g; cerelose, 5 g; cobalt chloride hexahydrate, 2 mg;silicone defoamer (SAG 471), 0.5 mL; pre-sterilization pH 4.95-5.00,adjusted with concentrated sulfuric acid. The fermentors, containingsecondary-seed medium, are sterilized for 20 minutes at 121° using bothjacket and injection steam. The agitation rate during sterilization is200 r.p.m. Post-sterilization, the medium pH is adjusted to 5.0 usingsterile sulfuric acid (5%). Absidia coerulea ATCC 6647 is incubated at28° using the following initial parameters: agitation, 100 r.p.m.; backpressure=5 psig; airflow=2.5 SLM (0.25 VVM); low DO set-point, 50%; pHcontrol, none. When the DO first drops to 30%, the airflow is increasedto 5 SLM (0.5 VVM). When the culture reaches low DO again, 30% DO ismaintained using agitation control. Secondary-seed cultures areharvested about 76 hours post-inoculation, when the OUR is between about4 and about 7 mM/L/h.

[0210] (C) Steroid Bioconversion

[0211] Ten-liter steroid-bioconversion fermentations are inoculatedusing 500 mL vegetative secondary-seed culture (5% [v/v] inoculationrate). Steroid-bioconversion medium contains (per liter of RO water):dextrin, 50 g; soyflour, 35 g; cerelose, 20 g; silicone defoamer (SAG471), 0.5 mL; pre-sterilization pH 2.95-3.00, adjusted with concentratedsulfuric acid. Sterilization conditions are as described forsecondary-seed medium. Post-sterilization, the medium pH is adjusted to3.0 using sterile sulfuric acid (5%). Absidia coerulea ATCC 6647 isincubated at 28° using the same initial parameters as those used forsecondary-seed cultivation. At about 17 hours post-inoculation, 200 gmicronized 5-androsten-3β-ol-17-one, slurried in a minimal volume of0.2% octylphenoxypolyethoxyethanol, is added to the 10-L fermentation.

[0212] Bioconversion cultures are assayed on a daily basis for5-androsten-3β,7β,11α-triol-17-one using TLC, as described in EXAMPLE 1.Bioconversion of 5-androsten-3β-ol-17-one to5-androsten-3β,7β,11α-triol-17-one is complete approximately 6-7 dayspost-inoculation.

[0213] (D) Isolation Procedure

[0214] The whole beer solids are recovered by centrifugation. The liquidis discarded. The rich solids are extracted using 10 liters of 85%acetone 15% water at 45° C. to 50° C. and the warm extract is clarifiedby filtration. The rich filtrate is concentrated by distillation toremove acetone generating an aqueous slurry of crude crystals. Thecrystal slurry is filtered and the mother liquor is discarded. Thewater-wet crystals are triturated in 600 milliliters of methylenechloride to remove impurities, dissolved in 700 milliliters of methanol(by heating to 55° C.), and then decolorized with 5 grams of Darco G-60carbon. After filtration to remove carbon, the filtrate is concentratedto crystallize the product. The methanol is removed further by adding300 mL of n-butyl acetate and concentrating to a thick crystal slurry.The crystals are filtered, washed with n-butyl acetate, and dried togive 75.5 grams of crude crystalline 5-androsten-3β,7β,11α-triol-17-one.

[0215] The crude crystals are triturated in 600 milliliters of methylenechloride to remove additional impurities, dissolved in 700 millilitersof methanol (by heating to 55° C.), and then decolorized with 5 grams ofDarco G-60 carbon. After filtration to remove carbon, the filtrate isconcentrated to crystallize the product. The methanol is removed furtherby adding 300 mL of n-butyl acetate and concentrating to a thick crystalslurry. The crystals are filtered, washed with n-butyl acetate, anddried to give 42.1 grams of purified crystalline5-androsten-3β,7β,11α-triol-17-one.

Example 6

[0216] Preparation of 5,9(11)-androstadien-3β-ol-17-one from5-androsten-3β,11α-diol-17-one

[0217] Step 1

[0218] To a slurry of 5-androsten-3β,11α-diol-17-one (30.4 g, 100 mmol)in CH₂Cl₂ (300 mL) was added TMEDA (18.1 mL, 120 mmol). The slurry wascooled to −10° C. and methyl chloroformate (7.72 mL, 100 mmol) added.The reaction was allowed to warm to room temperature. The reaction wasnot complete by TLC so more methyl chloroformate (772 μL, 10 mmol) wasadded. When the reaction was determine to be complete by TLC, EtOAc (300mL) and H₂O (100 mL) were added and the resulting layers separated. Theorganic phase was washed with 50 mL H₂O, dried over MgSO₄ andconcentrated to an oil which solidified on standing. The crude productwas recrystallized from hot EtOAc/CH₂Cl₂ and heptane. The slurry wasfurther cooled to 0-5° C. and the product collected by filtration (22 g,60.8% chemical). The carbonate was further purified by columnchromatography over silica gel eluting with a gradient of 5%-20%acetone/CH₂Cl₂ to obtain pure mono carbonate (20.57, 56.8%).

[0219] Step 2

[0220] The carbonate of step 1 (38.0 g, 0.105 mol) was dissolved in 570mL of THF and cooled to −35° C. Solid PCl₅ (37.1 g, 0.178 mol) wasslowly added keeping the temperature below −30° C. When TLC showedcomplete reaction the mixture was poured into cold NaHCO₃ solution andthe product extracted with ethyl acetate. The organic layers were driedover MgSO₄ and concentrated to afford an oil.

[0221] Step 3

[0222] This oil of step 2 was dissolved in methanol (500 ml) and treatedwith 36.1 g of K₂CO₃ and the mixture stirred at room temperature 15 hr.The residual carbonate was removed by filtration. The solution waspartially concentrated and water added to precipitate the desired dienicalcohol, which was dried in an oven at 45° C. Yield 29.52 g.

1. A 7β-hydroxy steroid of the formula (II)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

where Z₁-Z₂ is either a single bond, or a double bond.
 2. The 7β-hydroxysteroid (II) according to claim 1 where R₃ is H
 3. The 7β-hydroxysteroid (TI) according to claim 2 where R₃ is —C(O)—CH₃.
 4. The7β-hydroxy steroid (II) according to claim 1 where R₁₇ and R₁₈ form ═O.5. The 7β-hydroxy steroid (II) according to claim 1 where R₁₇, R₁₈, andthe C17 carbon atom of the steroid backbone form the lactone ring. 6.The 7β-hydroxy steroid (II) according to claim 5 where the lactone ringhas the α and β stereochemistry shown in the formula


7. The 7β-hydroxy steroid (II) according to claim 1 where the 7β-hydroxysteroid (II) is 5-androsten-3β,7β-diol-17-one.
 8. The 7β-hydroxy steroid(II) according to claim 1 where the 7β-hydroxy steroid (II) is5,9(11)-androstadien-3β,7β-diol-17-one.
 9. A 11α-hydroxy steroid of theformula (III)

where R₃is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula


10. The 11α-hydroxy steroid (III) according to claim 9, wherein R₃ is H.11. The 11α-hydroxy steroid (III) according to claim 10, wherein R₃ is—C(O)—CH₃.
 12. The 11α-hydroxy steroid (III) according to claim 9,wherein R₁₇ and R₁₈ form ═O.
 13. The 11α-hydroxy steroid (III) accordingto claim 9, wherein R₁₇, R₁₈, and the C17 of the steroid backbone formthe lactone ring.
 14. The 7β-hydroxy steroid (II) according to claim 13,where the lactone ring has the α and β stereochemistry shown in theformula


15. The 11α-hydroxy steroid (III) according to claim 9, wherein the11α-hydroxy steroid is 5-androsten-3β, 11α-diol-17-one.
 16. A7β,11α-dihydroxy steroid of the formula (IV)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula


17. The 7β,11α-dihydroxy steroid (IV) according to claim 16, wherein R₃is H.
 18. The 7β,11α-dihydroxy steroid (IV) according to claim 17,wherein R₃ is —C(O)—CH₃.
 19. The 7β,11α-dihydroxy steroid (IV) accordingto claim 16, wherein R₁₇ and R₁₈ form ═O.
 20. The 7β,11α-dihydroxysteroid (IV) according to claim 16, wherein R₁₇, R₁₈, and the C17 carbonatom of the steroid backbone form the lactone ring.
 21. The 7β-hydroxysteroid (II) according to claim 16, where the lactone ring has the α andβ stereochemistry shown in the formula


22. The 7β,11α-dihydroxy steroid (IV) according to claim 16, wherein the7β,11α-dihydroxy steroid (IV) is 5-androsten-3β,7β,11α-triol-17-one. 23.A process for the preparation of a 7β-hydroxy steroid of the formula(II)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

where Z₁-Z₂ is either a single bond, or a double bond, the processcomprising (1) contacting a Δ⁵-steroid of formula (I)

where R₃, R17, R₁₈, and Z₁-Z₂ are as defined above, with 7β-hydroxylaseof Diplodia.
 24. The process for the preparation of a 7β-hydroxy steroid(II) according to claim 23 wherein R₃ is H.
 25. The process for thepreparation of a 7β-hydroxy steroid (II) according to claim 24 whereinR₃ is —C(O)—CH₃.
 26. The process for the preparation of a 7β-hydroxysteroid (II) according to claim 23 wherein R₁₇ and R₁₈ form ═O.
 27. Theprocess for the preparation of a 7β-hydroxy steroid (II) according toclaim 23 wherein R₁₇, R₁₈, and the C17 carbon atom of the steroidbackbone form the lactone ring.
 28. The process for the preparation of a7β-hydroxy steroid (II) according to claim 23, where the lactone ringhas the α and β stereochemistry shown in the formula


29. The process for the preparation of a 7β-hydroxy steroid (II)according to claim 23 where the 7β-hydroxy steroid (II) is5-androsten-3β,7β-diol-17-one.
 30. The process for the preparation of a7β-hydroxy steroid (II) according to claim 23 where the 7β-hydroxysteroid (II) is 5,9(11)-androstadien-3β,7β-diol-17-one.
 31. The processfor the preparation of a 7β-hydroxy steroid (II) according to claim 23where the contacting is by fermentation, cell concentrate, whole cellsor cell-free reaction.
 32. The process for the preparation of a7β-hydroxy steroid (II) according to claim 31 where the contacting is byfermentation.
 33. The process for the preparation of a 7β-hydroxysteroid (II) according to claim 23 where the Diplodia is Diplodiagossypina.
 34. A process for the preparation of a 11α-hydroxy steroid ofthe formula (III)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

the process comprising: (1) contacting a Δ⁵-steroid of formula (I)

where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is a singlebond with 11α-hydroxylase of Aspergillus.
 35. The process for thepreparation of a 11α-hydroxy steroid (III) according to claim 34 whereinR₃ is H.
 36. The process for the preparation of a 11α-hydroxy steroid(III) according to claim 35 wherein R₃ is —C(O)—CH₃.
 37. The process forthe preparation of a 11α-hydroxy steroid (III) according to claim 34where R₁₇ and R₁₈ form ═O.
 38. The process for the preparation of a11α-hydroxy steroid (III) according to claim 34 wherein R₁₇, R₁₈, andthe C17 carbon atom of the steroid backbone form the lactone ring. 39.The process for the preparation of a 11α-hydroxy steroid (III) accordingto claim 34 wherein the lactone ring has the α and β stereochemistryshown in the formula


40. The process for the preparation of a 11α-hydroxy steroid (III)according to claim 34 where the 11α-hydroxy steroid is5-androsten-3β,11α-diol-17-one.
 41. The process for the preparation of a11α-hydroxy steroid (III) according to claim 34 where the contacting isby fermentation, cell concentrate, whole cells or cell-free reaction.42. The process for the preparation of a 11α-hydroxy steroid (III)according to claim 41 wherein the contacting is by fermentation.
 43. Theprocess for the preparation of a 11α-hydroxy steroid (III) according toclaim 34 where the Aspergillus is Aspergillus ochraceus.
 44. A processfor the preparation of a 7β,11α-dihydroxy steroid of the formula (IV)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

the process comprising (1) contacting a 7β-hydroxy steroid of formula(II)

where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is a singlebond with 11α-hydroxylase of Aspergillus.
 45. The process for thepreparation of a 7β,11α-dihydroxy steroid (IV) according to claim 44where R₃ is H.
 46. The process for the preparation of a 7β,11α-dihydroxysteroid (IV) according to claim 45 where R₃ is —C(O)—CH₃.
 47. Theprocess for the preparation of a 7β,11α-dihydroxy steroid (IV) accordingto claim 44 where R₁₇ and R₁₈ form ═O.
 48. The process for thepreparation of a 7β,11α-dihydroxy steroid (IV) according to claim 44,wherein R₁₇, R₁₈, and the C17 carbon atom of the steroid backbone formthe lactone ring.
 49. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 48 wherein the lactonering has the α and β stereochemistry shown in the formula


50. The process for the preparation of a 7β,11α-dihydroxy steroid (IV)according to claim 48 where the 7β,11α-dihydroxy steroid (IV) is5-androsten-3β,7β,11α-triol-17-one.
 51. The process for the preparationof a 7β,11α-dihydroxy steroid (IV) according to claim 48 where thecontacting is by fermentation, cell concentrate, whole cells orcell-free reaction.
 52. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 51 where the contactingis by fermentation.
 53. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 48 where theAspergillus is Aspergillus ochraceus.
 54. A process for the preparationof a 7β,11α-dihydroxy steroid of the formula (IV)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

the process comprising (1) contacting a Δ⁵-steroid of formula (I)

where R₃, R₁₈, and R₁₇ are as defined above and where Z₁-Z₂ is a singlebond with 7β-hydroxylase of Diplodia to produce a 7β-hydroxy steroid offormula (II)

where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is a singlebond; and (2) contacting the 7β-hydroxy steroid (II) of step (1) with11α-hydroxylase of Aspergillus.
 55. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 54 where R₃ is H. 56.The process for the preparation of a 7β,11α-dihydroxy steroid (IV)according to claim 55 where R₃ is —C(O)—CH₃.
 57. The process for thepreparation of a 7β,11α-dihydroxy steroid (IV) according to claim 54where R₁₇ and R₁₈ form ═O.
 58. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 54 where R₁₇ and R₁₈together with the C17 carbon atom of the steroid backbone to which theyare bound form the lactone ring.
 59. The process for the preparation ofa 7β,11α-dihydroxy steroid (IV) according to claim 54 wherein thelactone ring has the α and β stereochemistry shown in the formula


60. The process for the preparation of a 7β,11α-dihydroxy steroid (IV)according to claim 54 where the 7β,11α-dihydroxy steroid (IV) is5-androsten-3β,7β,11α-triol-17-one.
 61. The process for the preparationof a 7β,11α-dihydroxy steroid (IV) according to claim 54 where thecontacting is by fermentation, cell concentrate, whole cells orcell-free reaction.
 62. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 61 where the contactingis by fermentation.
 63. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 61 where the Diplodiais Diplodia gossypina.
 64. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 61 where theAspergillus is Aspergillus ochraceus.
 65. The process for thepreparation of a 7β,11α-dihydroxy steroid (IV) according to claim 54where the 7β-hydroxy steroid (II) of step (1) is not isolated prior tothe contacting of step (2).
 66. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 54 where the 7β-hydroxysteroid (II) of step (1) is isolated prior to the contacting of step(2).
 67. A process for the preparation of a 7β,11α-dihydroxy steroid ofthe formula (IV)

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

the process comprising (1) contacting a Δ⁵-steroid of formula

where R₃, R₁₈, and R₁₇ are as defined above and where Z₁-Z₂ is a singlebond with the 7β,11α-hydroxylase(s) of Absidia.
 68. The process for thepreparation of a 7β,11α-dihydroxy steroid (IV) according to claim 67where R₃ is H.
 69. The process for the preparation of a 7β,11α-dihydroxysteroid (IV) according to claim 68 where R₃ is —C(O)—CH₃.
 70. Theprocess for the preparation of a 7β,11α-dihydroxy steroid (IV) accordingto claim 67 where R₁₇ and R₁₈ form ═O.
 71. The process for thepreparation of a 7β,11α-dihydroxy steroid (IV) according to claim 67where R₁₇ and R₁₈ together with the C17 carbon atom of the steroidbackbone to which they are bound form the lactone ring.
 72. The processfor the preparation of a 7β,11α-dihydroxy steroid (IV) according toclaim 67 wherein the lactone ring has the α and β stereochemistry shownin the formula


73. The process for the preparation of a 7β,11α-dihydroxy steroid (IV)according to claim 67 where the 7β,11α-dihydroxy steroid (IV) is5-androsten-3β,7β,11α-triol-17-one.
 74. The process for the preparationof a 7β,11α-dihydroxy steroid (IV) according to claim 67 where thecontacting is by fermentation, cell concentrate, whole cells orcell-free reaction.
 75. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 74 where the contactingis by fermentation.
 76. The process for the preparation of a7β,11α-dihydroxy steroid (IV) according to claim 67 where the Absidia isAbsidia coerulea.
 77. A process for the preparation of a 5,9(11)-androstadien of formula I

where R₃ is: (1) —H; (2) —CO—R₄ where R₄ is H or C₁-C₅ alkyl; where R₁₇and R₁₈ together form ═O or where R₁₇ and R₁₈ together with the C17carbon atom of the steroid backbone to which they are bound form alactone ring of the formula

and where Z₁-Z₂ is a double bond, the process comprising: (1) providinga compound of the formula (III)

where R₃, R₁₇, and R₁₈ are as defined above; and (2) eliminating the 11αhydroxyl group to form the double bond between Z₁and Z₂ (formula I). 78.The process of claim 77, wherein the step of providing the compound offormula III includes contacting a Δ⁵-steroid of formula (I)

where R₃, R₁₇, and R₁₈ are as defined above and where Z₁-Z₂ is a singlebond with 11α-hydroxylase of Aspergillus.